check engine SSANGYONG MUSSO 2003 Owners Manual

OM600 ENGINE MECHANICAL 1B3-139
CAMSHAFT Preceding Work : Removal of cylinder head cover
1 Bolt............................................................ 25Nm
2 Washer
3 Camshaft Bearing Cap
4 Camshaft
5 Dowel Pin
6 Locking Washer
7 Timing Chain 8 Cylinder Head
9 Oil Pan
10 Camshaft Sprocket
11 Washer
12 12-Sided Bolt (M11) ... ..........Check, 25Nm + 90 °
13 Gasket ................................................... Replace
14 Chain Tensioner ........................................ 80Nm

1B3-142 OM600 ENGINE MECHANICAL
4. Install the camshaft bearing caps according to markings(1,2, 3 etc.).
7. Remove the camshaft bearing cap.
8. Pull off the camshaft.
Notice
Be careful not to miss front locking washer.
9. Pull out the locking washer.Notice Check the condition of locking washer and replace if
necessary.
Installation Procedure
1. Insert the locking washer.
2. Check the valve tappet and ensure that tappet moves smoothly.
3. Coat the camshaft with oil and install the camshaft onto the cylinder head so that the TDC marking (arrow) is positioned
upward vertically.

1B3-144 OM600 ENGINE MECHANICAL
10. Check the TDC marking of OT on the crankshaft.8. Install the chain tensioner.
Tightening Torque 80 Nm
Notice Replace the seal.Before installation, by pumping in the oil approx. 10 times, fill the oil.
9. Remove the engine lock.
Notice If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm,
replace it.

1B3-150 OM600 ENGINE MECHANICALIn this position, the marking on camshaft / camshaft bearing cap (arrow) must also be aligned. If the markings are notaligned, the timing chain must be re-set and the injectionpump timing has to be set.
14. Position the no.1 cylinder at TDC.
11. Place the fitting tool (8) onto the chain link and rivet thechain pins one by one.
12. Check the riveting of chain pins and re-rivet if necessary.
13. Remove the wire.
Tightening Torque 35 - 40 Nm

1B3-158 OM600 ENGINE MECHANICAL
CRANKSHAFT SPROCKET
Preceding Work : Removal of oil panRemoval of timing case cover
1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90 °
2 Washer
3 Camshaft Sprocket
4 Timing Chain
5 Bearing Pin
6 Bearing Pin
7 Oil Pump
8 Oil Pump Sprocket
9 Oil Pump Chain
10 Washer 11 Bolt
............................................................ 25Nm
12 Crankshaft Sprocket
13 Crankshaft
15 Key
16 Guide Rail
17 Spring
18 Bushing
19 Tensioning Lever

OM600 ENGINE MECHANICAL 1B3-161
Installation Procedure
1. Put the same alignment mark on the new crankshaftsprocket as in the old sprocket. Notice Check the timing chain, camshaft sprocket, injection pump timing sprocket, oil pump chain and oil pump sprocket for
wear and replace if necessary.
2. Install the new crankshaft sprocket (12) by using a drift (21). Notice Align the groove of sprocket and woodruff key (arrow)
exactly. Drift 116 589 07 15 00
3. Fit the timing chain (4) on the crankshaft sprocket (12). Notice Align the alignment marks (arrow) on the chain and sprocket.
4. Install the camshaft sprocket (3).
Tightening Torque 25 Nm + 90 °
Notice Pay attention on the alignment marks and dowel pin (arrow).

OM600 ENGINE MECHANICAL 1B3-163
PISTON
Preceding Work : Removal of the cylinder headRemoval of the oil pump
1 Oil Ring
2 2nd Ring
3 Top Ring
4 Snap Ring.............................................. Replace
5 Piston Pin
6 Piston
7 Connecting Rod Bushing .......................... Check 8 Connecting Rod
9 Connecting Rod Upper Bearing Shell
10 Connecting Rod Lower Bearing Shell 11 Connecting Rod Bearing Cap
12 Connecting Rod Bolt ......................... 35Nm + 90 °
13 Crankcase
14 Cylinder Bore
Notice There are two kinds of connecting rods (for machining) and they are different in weight approx. 15g. When replacing the connecting rod, measure its weight and ensure that a engine has the same weight of connecting rods. If not, there would be a unbalancing of engine.

1B3-166 OM600 ENGINE MECHANICAL Installation Procedure
1. Fit the piston onto the connecting rod so that the arrow(15) and the locking slot (16) are facing in direction of the vehicle.
2. Coat the piston pin (15) with engine oil and insert it by hand. Notice Do not heat up the piston.
3. Install the new snap ring (4) into the grooves (arrow).
4. Check the piston rings (1, 2, 3) and replace them if necessary.
5. Install and arrange the piston rings to be evenly 120 ° from
each ends gap.

1B3-168 OM600 ENGINE MECHANICAL
12. Coat the bolts (12) with oil and then tighten the bolts.
Tightening Torque40Nm + 90°
13. Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft.
14. Measure clearance between the piston crown and cylinder
Standard Max. 0.12mm
15. Position the piston at TDC and measure the distance between the piston crown and the crankcase surface.
Notice Measure at points marked. Dial Gauge 001 589 00 53 21
Dial Gauge Holder 363 589 02 21 00
Standard Max. 0.965 mm

OM600 ENGINE MECHANICAL 1B3-179
Measurement Procedure
1. Measure height ‘A’ .
Limit 142.5 mm
Notice If the height is less than 142.5mm, replace the cylinder head.
2. Insert the valve (1) and measure valve arrears ‘a’.
Valve Arrears ‘a’ 0.1 - 0.7 mm
Notice If out of standard, machine the valve seat.
3. Install the prechamber and measure protrusion ‘C’.
Protrusion ‘C’ 7.6 - 8.1mm
4. Assemble the engine and check the valve timing.